High-density plug connector for twisted pair cable

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/264,763 filed Jan. 29, 2001, the complete disclosure of which is hereby expressly incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an electrical connector system for high-density interconnection of data cables and the like, and in particular, to an improved high-density plug electrical connector.

2. Summary of the Prior Art

It is common in building wiring closets where hubs and routers are located for distribution and/or storage of data, to have a plurality of racks and panels with multiple electrical interconnections formed by multiple cables. It is commonplace to have such electrical connections made by connection systems commonly known as modular plugs and jacks, the so-called RJ-45 connection system, or other systems such as the RJ-21. Separate connection systems have traditionally been used, due to the speed of the data, the need to minimize EMI radiation, as well as the need to minimize cross talk between adjacent lines in the same connector.

One electrical connection system useful with data interconnections as described above is shown in U.S. Pat. No. 5,649,829 to Miller et al. This connector system is generally known as the CHAMP system and includes a D-shaped mating face, a plurality of electrical terminals for mating to a like connector, and wire connecting sections including insulation displacement contacts. While this connector system is an industry-wide accepted system for telecommunication connections, its main use is when space is not at a premium.

Another connector system is shown in U.S. Pat. No. 5,380,223 to Marsh et al., which is a shielded connector having a plurality of terminals extending to a rear of the connector, where a contact portion is intended to be soldered to cable conductors. This electrical connector, however, was designed for use with a PCMCIA card and does not contain the required density required for the present application.

The objects of the invention are to improve upon the shortcomings as mentioned above.

SUMMARY OF THE INVENTION

The objects of the invention have been accomplished by providing an electrical connector, comprising an insulative housing body assembly comprised of two bi-partite housing portions. Each housing portion includes first and second rows of terminal receiving cavities, a first row adjacent to a first major surface of each the housing portion, and a second row adjacent to a second major surface of each housing portion. The two housing portions are adaptable for stacking together with the second major surface of each housing portion proximate. A plurality of electrical terminals are included where each terminal includes a front contact portion, an intermediate body section, and a rear wire connecting section, the rear wire connecting section comprising a blade section adapted to receive a wire in soldered connection.

Preferably, the connector portions are hermaphroditic. The housing portions include an upstanding alignment post on one side of the second major surface, and a corresponding alignment aperture on a laterally disposed side, whereby when the hermaphroditic housing portions are stacked one above the other, corresponding alignment posts and apertures assure proper alignment. Preferably, the lateral centerline of the terminal receiving cavities is offset from the centerline between the alignment post and alignment aperture.

The terminal receiving cavities are comprised of a front open channel to receive the front contact portions, and a rear open portion allowing access to the rear wire connecting sections. Each housing portion is comprised of front and rear sections, the front section including the front open channels, and the rear section includes the rear open portions. The terminal receiving cavities further comprise intermediate cavity portions for retaining the terminals. The front and rear housing sections include latching mechanisms to retain the two members together. Preferably, the electrical connector further comprises an outer shielding shell enclosing the housing body assembly. The outer shielding shell is profiled to back up the latching mechanisms preventing the latching mechanisms from coming unlatched.

Also preferably, the rear wire connecting sections of the terminals include an L-shaped conductive member, comprised of the flat blade section and a wall section extending from a side edge thereof. Housing portions include wire alignment recesses positioned forward of said rear wire connecting sections, whereby wire ends may be inserted into the wire alignment recesses, assuring alignment over the wire connecting sections. The electrical connector is arranged for connection to twisted pair cable, with side-by-side terminals in the same row being adapted for connection to a twisted pair of conductors, the terminals being arranged with the L-shaped sections back-to-back with a thin web of material between them to minimize the centerline spacing between pairs.

In yet another embodiment of the invention, an electrical connector, comprises an insulative housing body having at least two cantilevered housing sections extending from a main body portion, the cantilevered housing sections being positioned vertically above one another in a laterally offset manner. Each cantilevered housing section including first and second rows of terminal receiving cavities, a first row adjacent to a outside surface of each housing portion, and a second row adjacent to an inside surface of each housing portion. A plurality of electrical terminals is positioned in the housing body where each terminal includes a front contact portion, an intermediate body section, and a rear wire connecting section.

In the preferred embodiment, the rear wire connecting section comprises a blade section adapted to receive a wire in soldered connection. The rear wire connecting sections of the terminals include an L-shaped conductive member, comprised of the flat blade section and an integral wall section extending from a side edge thereof. Preferably, the housing portions include wire alignment recesses positioned forward of the rear wire connecting sections, whereby wire ends may be inserted into the wire alignment recesses, assuring alignment over the wire connecting sections. The electrical connector is arranged for connection to twisted pair cable, with side-by-side terminals in the same row being adapted for connection to a twisted pair of conductors, the terminals being arranged with the L-shaped sections back-to-back with a thin web of material between them to minimize the centerline spacing between pairs.

In the preferred embodiment of the invention, the insulative housing body is comprised of two housing portions, each housing portion having a cantilevered housing section. Preferably, the housing portions are hermaphroditic. The housing portions include an upstanding alignment post on one side of the second major surface, and a corresponding alignment aperture on a laterally disposed side, whereby when the hermaphroditic housing portions are stacked one above the other, corresponding alignment posts and apertures assure proper lateral offset alignment.

Preferably, the terminal receiving cavities are comprised of a front open channel to receive the front contact portions, and a rear open portion allowing access to the rear wire connecting sections. Each housing portion is comprised of front and rear sections, the front section including the front open channels, and the rear section includes the rear open portions. The terminal receiving cavities further comprise intermediate cavity portions for retaining the terminals.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view showing the plug connector and receptacle connector poised for interconnection;

FIG. 2 shows an exploded perspective view of the plug connector of FIG. 1;

FIG. 3 shows a top front perspective view of one of the 2-piece hermaphroditic housing portions shown in FIG. 2;

FIG. 4 shows a top rear perspective view of the 2-piece hermaphroditic housing portions shown in FIG. 3;

FIG. 5 shows a front portion of the hermaphroditic connector housing shown in FIG. 4;

FIG. 6A shows a plan view of the housing from the perspective showing the alignment post and corresponding alignment opening;

FIG. 6B shows a plan view similar to that of FIG. 6A showing the opposite side;

FIG. 7A shows a cross-sectional view through Lines <b>7</b>A—<b>7</b>A of FIG. 6B;

FIG. 7B shows a cross-sectional view through Lines <b>7</b>B—<b>7</b>B of FIG. 7A;

FIG. 8 shows a perspective view of the rear portion of the hermaphroditic connector housing shown in FIG. 4;

FIG. 9 shows a plan view of the rear portion of the hermaphroditic connector housing shown in FIG. 4;

FIG. 10 shows a perspective view of some of the terminals for the connector shown in FIG. 2;

FIG. 11 shows a perspective view of some of the terminals for the connector shown in FIG. 2;

FIG. 12 shows the shield shroud of the plug connector of FIG. 1;

FIG. 13 shows a top view of a first shield shell for the plug connector;

FIG. 14 shows the underside of the shield shell of FIG. 13; and

FIG. 15 shows a perspective view showing the terminals poised for receipt in the housing portions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With respect first to FIG. 1, an electrical interconnection is shown as comprised of a plug connector <b>2</b> and a receptacle connector <b>4</b>. The plug connector <b>2</b> is adapted to be connected to a shielded cable <b>6</b> which preferably contains a plurality of twisted pair conductors, whereas receptacle <b>4</b> is adapted to be connected to a printed circuit board (not shown). Both electrical connectors are fully shielded where the plug connector <b>2</b> includes a shielded enclosure <b>8</b> which is preferably a die-cast housing of two similar halves, whereas receptacle <b>4</b> includes a shield <b>10</b> which in the preferred embodiment is a stamped metallic housing.

Each electrical connector also includes a mating interface comprised of a shielding shroud, plug connector <b>2</b> having a shielding shroud shown generally at <b>12</b> which is profiled to receive in shielding engagement, the shielding shroud <b>14</b> of receptacle <b>4</b>. Finally, plug connector <b>2</b> includes elongate jackscrews <b>16</b> and <b>18</b> which are profiled for threaded engagement with complementary threaded posts <b>20</b> and <b>22</b>, respectively, of the receptacle <b>4</b>. It should be appreciated that, when the jackscrews <b>16</b>, <b>18</b> are fully threaded into their respective threaded posts <b>20</b>, <b>22</b>, the two electrical connectors <b>2</b>, <b>4</b> are in a fully mated condition where electrical terminals within plug connector <b>2</b> are fully electrically engaged with electrical terminals in receptacle. While the mating interface of the plug and receptacle connectors will be described in general, this aspect is described even more fully in co-pending patent application filed on even date as Ser. No. 60/264,761 (attorney's docket number 17628), incorporated herein by reference. Furthermore, the receptacle connector <b>4</b> is the subject of co-pending patent application filed on even date as Ser. No. 60/264,760 (attorney's docket number 17630), incorporated herein by reference.

With respect now to FIG. 2, the plug connector <b>2</b> is shown in an exploded manner for better clarity. It should be appreciated that the shielding shell <b>8</b> as shown in FIG. 1 is comprised of bi-partite halves <b>30</b> and <b>32</b>. The plug connector <b>2</b> further comprises housing portions <b>34</b> and <b>38</b> carrying a plurality of electrical terminals <b>36</b>. The plug connector <b>2</b> further includes a pair of wire organizing blocks at <b>42</b> to arrange the twisted pairs in alignment with the terminals and a pair of wire dressing blocks <b>44</b>.

With reference now to FIGS. 3-9, the housing members <b>34</b> and <b>38</b> will be described in greater detail.

With reference first to FIG. 3, the housing <b>34</b> is shown in greater detail, and it should be understood that housings <b>34</b> and <b>38</b> are identical and hermaphroditic, thus only one such housing will be described in detail. Housings <b>34</b> generally include a front housing portion <b>50</b> and a rear housing portion <b>52</b>. The housing <b>34</b> generally includes a front cantilevered section <b>54</b> extending from a main body portion <b>56</b> of the housing portion. Furthermore, cantilevered section <b>54</b> includes a surface <b>58</b> and an oppositely directed face at <b>60</b>, both of which include terminal receiving cavities <b>62</b> to receive the plurality of electrical terminals <b>36</b>. The rear housing portion <b>52</b> correspondingly includes a plurality of open-faced wire receiving channels <b>64</b> to receive wires in alignment with the terminals <b>36</b>. The wire receiving channels <b>64</b> are best shown in FIG. 4, which is the rear perspective view.

With respect now to FIG. 5, the front housing portion <b>50</b> will be described in greater detail. It should be understood that the view in FIG. 5 is not only from the rear of the connector half, but it also has been flipped around its axial center line, whereby a mounting surface designated at <b>70</b> is shown. This surface <b>70</b> is an inner surface of the main body portion <b>56</b> and includes an upstanding alignment post <b>72</b> and a corresponding alignment aperture at <b>74</b>. The housing <b>50</b> also includes a rear face at <b>76</b> through which the terminal receiving cavities <b>62</b> extend. The rear face <b>76</b> also includes alignment bars <b>78</b> extending therefrom, which, in the preferred embodiment, are of substantial trapezoidal shape so as to provide a polarizing feature with the rear housing portion <b>52</b>. The housing portion further comprises a latch arm <b>80</b> extending along the side of the main body portion <b>56</b>, two latch arms <b>82</b> having latching openings <b>84</b>, and finally includes a latch projection at <b>86</b>.

With reference now to FIG. 7B, the terminal receiving cavities <b>62</b> in housing portion <b>50</b> include intermediate cavity portions <b>90</b> leading into open upper facing channels <b>92</b>, which actually receive the terminals <b>36</b>. It should be appreciated that terminal receiving cavities <b>62</b> extend in two rows for each housing portion <b>50</b>, both rows extending through rear face <b>76</b> of housing portion <b>50</b>, where one row opens up onto surface <b>58</b>, whereas the other row opens onto surface <b>60</b>.

With respect now to FIG. 8, rear housing portion <b>52</b> generally comprises a wall <b>100</b>, an opposite wall <b>102</b>, and side walls <b>104</b> and <b>106</b> extending between leading face <b>108</b>, and rear face <b>109</b>. The leading face <b>108</b> includes trapezoidal openings at <b>110</b> as well as a plurality of rear terminal receiving cavities <b>112</b>. It should be appreciated that the cavities <b>112</b> are arranged in pairs, and are generally L-shaped in configuration. As shown best in FIG. 9, each of the cavities <b>112</b> includes a horizontal cavity portion <b>114</b> and an upstanding portion <b>116</b>. It should be appreciated that the pairs are arranged such that upstanding portions <b>116</b> are arranged in back-to-back arrangement with a thin web of material <b>118</b> disposed therebetween. A further web of material <b>120</b> is disposed between adjacent terminals of a different pair. Finally, the cavities <b>112</b> include a concave opening <b>122</b> facing the L-shaped cavity <b>112</b> which will be described herein. Finally, housing portion <b>52</b> includes a cantilevered latch arm <b>126</b> and latch projections <b>128</b> and <b>130</b> as described herein.

With respect now to FIGS. 10 and 11, the terminals <b>36</b> will be described in greater detail. It should be appreciated that the terminals <b>36</b>, have two different symmetries and therefore have been designated <b>36</b>A and <b>36</b>B in FIGS. 10 and 11. Thus, terminals <b>36</b>A and <b>36</b>B are profiled to be received in respective cavities <b>112</b>A and <b>112</b>B. With respect first to terminal <b>36</b>A, the terminal includes a front contact portion <b>140</b>A having a central retaining portion <b>142</b>A and a wire connecting portion <b>144</b>A. The wire-connecting portion is comprised of a flat blade portion <b>146</b>A and an integral upstanding wall portion <b>148</b>A. The upstanding wall portion <b>148</b>A includes a retaining stop portion at <b>150</b>A. In a similar manner, terminal <b>36</b>B includes front contact portions <b>140</b>B, central retaining sections <b>142</b>B, and rear wire connecting sections <b>144</b>B. Likewise, wire-connecting section <b>144</b>B includes a flat blade section <b>146</b>B and an integral upstanding wall portion <b>148</b>B. Likewise, the upstanding wall portion <b>148</b>B includes a stop portion at <b>150</b>B.

With respect now to FIG. 12, the shielding shroud <b>12</b> is shown as including a base wall <b>160</b> having latch sections <b>162</b> extending therefrom, having latching openings at <b>164</b>. The base wall <b>160</b> further includes diametrically opposed openings at <b>166</b>, <b>168</b>. The shroud <b>12</b> further includes a peripheral shroud portion <b>170</b> which is a drawn shroud portion extending forwardly from the base wall <b>160</b>. The shroud section <b>170</b> includes a top shroud wall <b>172</b>, a lower shroud wall <b>174</b>, which is generally disposed parallel to upper wall <b>172</b>, where each of the walls includes stamped projections at <b>176</b> acting as shielding contacts, as is well known in the art. End wall <b>178</b> forms an obtuse angle relative to lower wall <b>174</b> and an acute angle with respect to <b>172</b>. On the opposite side of the shroud, a generally vertical upstanding wall portion is shown at <b>180</b> (vertical relative to wall <b>174</b>) which is continuous with a concave radiused portion at <b>182</b>. It should also be appreciated that apertures <b>166</b> and <b>168</b> are diametrically opposed in opposite corners of the base wall <b>160</b> where aperture <b>166</b> is positioned so as to be partially extending beneath wall portion <b>178</b>, with aperture <b>168</b> extending adjacent the concave radiused portion <b>182</b>. It should be appreciated that the concave radiused portion <b>182</b> provides enough room in the corner of the base wall to provide the aperture <b>168</b>.

With respect now to FIGS. 13 and 14, the shielding shells <b>30</b>, <b>32</b> will be described in greater detail. It should be appreciated that both FIGS. 13 and 14 depict shielding shell <b>30</b>, but that shielding shell <b>32</b> would be identical, with the exception of the cable entry opening orientation, as will be described. As shown best in FIGS. 13 and 14, shielding shell <b>30</b> is comprised of a generally flat wall portion <b>200</b> having a front opening portion at <b>202</b> and a rear cable-receiving portion at <b>204</b>. As shown in FIG. 14, the shielding shell <b>30</b> includes upstanding wall portions <b>206</b>, <b>208</b> having vertically oriented slots at <b>60</b>, <b>62</b> for placement of the shielding shroud as will be described herein.

As shown in FIG. 14, shielding shell <b>30</b> further includes complementary mounting blocks <b>220</b>, <b>222</b> where mounting block <b>220</b> includes a horizontally disposed through-hole <b>224</b> and a vertically disposed mounting aperture at <b>226</b>. Meanwhile, mounting block <b>222</b> includes a through-hole at <b>228</b> which will align with a mounting hole in the opposite shielding shell when the two shielding shells are placed together. The cable-receiving opening at <b>204</b> further includes openings at <b>230</b> and <b>232</b> which will also align with openings in the opposite shielding shell <b>32</b> when aligned. Finally, the shielding shell <b>30</b> includes a jackscrew support at <b>240</b> having a U-shaped section <b>242</b>, and a support member <b>244</b> having a U-shaped section <b>246</b>. On the opposite side, a jackscrew support is shown at <b>248</b> having a U-shaped section at <b>250</b>, whereas a support <b>252</b> has a U-shaped section at <b>254</b>.

With the plug connector components as described above, the assembly of the plug assembly <b>2</b> will be described in greater detail. With reference first to FIG. 2, the terminals <b>36</b> will be assembled within connector housing portions <b>34</b>, <b>38</b>. It should be appreciated that two rows of terminals <b>36</b> will be positioned in housing <b>34</b>, and two rows of terminals <b>36</b> will be positioned in housing <b>38</b>. This positions an end portion of terminals <b>36</b> adjacent a rear portion of their respective housings for soldering to respective conductors of multiconductor cable <b>6</b> (FIG. <b>1</b>). In the preferred embodiment, there are two rows of twelve terminals <b>36</b> in housing <b>34</b>, and two rows of twelve terminals <b>36</b> in housing <b>38</b>, or forty-eight terminals total, which will accommodate <b>24</b> twisted pair conductors. It should be appreciated from the description above relative to FIGS. 10 and 11 that a pair of terminals <b>36</b>A and <b>36</b>B are positioned in respective cavities <b>62</b>, such that front contact section <b>140</b>A of terminal <b>36</b>A resides in open channel <b>92</b>A, with central contact portion <b>142</b>A residing in cavity portion <b>90</b>A. Likewise, terminal <b>36</b>B is positioned in the cavity <b>62</b> such that front contact portion <b>140</b>B resides in open channel <b>92</b>B, with central contact portion <b>142</b>A residing in cavity portion <b>90</b>B. It should be appreciated that the contacts are all stitched in, in this fashion, which places the upstanding wall portions <b>148</b>A, <b>148</b>B of the terminals <b>36</b>A, <b>36</b>B in back-to-back relation throughout the housing. It should also be appreciated that the wire connecting portions <b>144</b>A, <b>144</b>B of all contacts still extend from the housing <b>50</b> at this point. The rear housing portions <b>52</b> are now positioned over the wire connecting portions <b>144</b>A, <b>144</b>B; with respective cavity portion <b>112</b>A, <b>112</b>B (FIG. 9) slidably received over all wire connecting portions <b>144</b>A, <b>144</b>B.

FIG. 15 shows two rows of terminals <b>36</b> poised for receipt within the respective housing <b>50</b>, with rear housing portion <b>52</b>, aligned for receipt over the terminal ends, and for snap latching the housing. The rear housing portion is slid forward until the rear housing <b>52</b> is latched into position with housing portion <b>50</b>, that is, latch <b>126</b> snaps over corresponding projection <b>86</b>; latch openings <b>84</b> of latch arms <b>82</b> snap over corresponding projections <b>128</b> (FIG. 8) where latch arm <b>80</b> snaps over corresponding projection <b>130</b> (FIG. <b>8</b>). This also traps portions <b>150</b>A, <b>150</b>B of terminals <b>36</b>A, <b>36</b>B within the housings, against shoulders defined in the respective housings <b>50</b>, <b>52</b>. It should be appreciated that this process continues, until two identical housings <b>34</b>, <b>38</b> are completed.

To assemble the conductors to the various terminals <b>36</b>, the twisted pairs, while still twisted, are inserted through apertures of wire organizing blocks <b>44</b> and then the wires are separated and placed in individual slots of the dressing blocks <b>42</b>. It should be appreciated that housing <b>34</b> and <b>38</b> are sandwiched together to form a housing assembly, therefore, the inside facing terminals are soldered first, and then the outer row of terminals <b>36</b> receive their respective wires. To perform the soldering function, the individual wires of the twisted pair are stripped, such that the length of the exposed conductor is longer than the length of the corresponding wire connecting sections <b>144</b>A, <b>144</b>B. The tip end of the conductor is inserted into the opening <b>122</b>, which by nature of its radiused configuration facing the wire connecting portions, directs the conductor in an organized fashion neatly in the pocket provided by the blade sections <b>146</b>A, <b>146</b>B and the wall portions <b>148</b>A, <b>148</b>B for soldering.

With reference now to FIGS. 6A and 7A, the assembly of the two stacked housings comprised of housings <b>34</b> and <b>38</b> will be described. As shown in FIG. 6A, the centerline CA between the alignment post <b>72</b> and the alignment opening <b>74</b> is offset by a distance O, from the centerline of the terminals CT. Thus, when the two hermaphroditic housings <b>34</b> and <b>38</b> are assembled by positioning respective alignment posts in respective alignment openings, the two cantilevered portions <b>54</b> are laterally staggered at the front face of the connector, as best shown in FIG. <b>1</b>.

With the housing comprised of housing portions <b>34</b> and <b>38</b> assembled as described above, the shielding shroud <b>12</b> can now be slidably received over the front portion thereof until the latching openings <b>164</b> latch with respective latch projections <b>66</b> (FIG. 3) on housing <b>34</b>, and a respective latching projection (not shown) on housing <b>38</b>. This latches the combination of the housing portions <b>34</b> and <b>38</b> to the shielding shroud <b>12</b>. The shielding shroud can then be placed in the shielded portion <b>32</b> such that the side edges of the front wall portion <b>160</b> of the shielding shroud <b>12</b> are received in slots <b>210</b> and <b>212</b> of a corresponding shielding shell <b>32</b>.

The jackbolts <b>16</b> and <b>18</b> are thereafter positioned in their respective positions, such that jackscrew <b>16</b> is positioned through a corresponding opening <b>224</b> and on platforms <b>240</b>, <b>244</b>, and jackscrew <b>18</b> is positioned on corresponding platforms <b>248</b>, <b>252</b>. The top portion <b>30</b> can thereafter be positioned above shielding shell <b>32</b> and threaded fasteners can be positioned through openings <b>270</b>, <b>272</b>, <b>274</b> (FIG. 2) to fasten the two shielding shells together. It should be appreciated that the cable <b>6</b> is dressed through the opening <b>204</b> and, in the preferred embodiment, would include a strain relief collar.

It should also be understood that the housings <b>34</b>, <b>38</b> together with the shielding shells provide a locking feature for the terminals. That is, the inside dimensions between the walls <b>200</b>, traps the housings together, as well as preventing enough clearance for the latch arms <b>82</b> to come unlatched. This provides enhanced pull out strength for the terminals.

To connect the two connectors <b>2</b>, <b>4</b> together, it should be appreciated that the shroud portion <b>14</b> of the receptacle <b>4</b> is inserted within shroud portion <b>12</b> of the plug <b>2</b>. It should be appreciated that, from the profile of the shroud for each of the plug and receptacle are mirror images of each other such that, when the two connectors are mated, the concave radiused portions correspond in overlapping relation. It should also be appreciated that this places the jackscrews <b>16</b>, <b>18</b> in alignment with the threaded inserts <b>20</b> and <b>22</b> to pull the two connectors into complete engagement.

Advantageously, the plug design as described above provides a high-density design, capable of accomplishing the requirements set out. Thus, the two stacking connector housings <b>34</b>, <b>38</b> allow individual wires to be soldered to their respective portions. Without the separate housings <b>34</b>, <b>38</b>, it would be difficult to access the inner wire connecting portions for soldering. Other types of wire connecting portions, such as crimp or insulation displacement styles, would not allow the small centerline spacing between the terminals. In the preferred embodiment of the invention, the centerline spacing between contact portions <b>140</b>A, <b>140</b>B in the same twisted pair combination is 1.0 mm; and the centerline spacing between adjacent contact portions between pairs is 1.5 mm. Thus, given the close centerline spacing and provision of a multiple of rows, the high-density nature of this plug connector is realized.